Roofing tile hangers and related assemblies

ABSTRACT

The invention provides roofing tile hanger plates for mounting one or multiple roofing tiles to the roof of a structure. The plates are designed to direct water away from the seams between horizontally adjacent roofing tiles and thereby reduce water penetration to an underlying roof structure.

FIELD OF THE INVENTION

This invention relates to the field of roofing tiles and their installation.

BACKGROUND OF THE INVENTION

Roofing tiles, such as stone and artificial stone roof tiling, are among the most popular as well as durable and attractive roofing options for both residential and commercial structures. However, a persistent concern with such roof tiling installations is water leakage and migration to the underlying roof, especially with respect to rain water that may migrate into the seams formed by adjacent tiles.

What is needed and provided by the present invention is a manner of installing roofing tiles that results in improved resistance to water leakage and other advantages as described herein.

SUMMARY OF THE INVENTION

One embodiment of the invention provides a roofing tile hanger plate that includes:

a vertical dimension, a horizontal dimension and an expansive surface on each of two sides,

at least one tile hanging portion having a horizontal dimension and sized and configured to attach to one at least substantially rectangular roofing tile, said tile hanging portion having a vertically-oriented horizontal midline and including:

-   -   a lower, tile overlaying and connecting portion having a bottom         edge and a linear top edge wherein on each side of the midline a         vertical recess (or “cutout”) is formed that extends from the         bottom edge of the lower, tile overlaying and connecting portion         toward but does not reach the top edge of the lower, tile         overlaying and connecting portion; and     -   a roof attachment portion extending above and from the lower,         tile overlaying and connecting portion.

A related embodiment of the invention provides a roofing tile mounting assembly, that includes:

a roofing tile hanger plate as described herein; and

an at least substantially rectangular at least substantially flat roofing tile, such as a rectangular roofing tile, having a top edge, a bottom edge, two side edges and an expansive surface on each side,

wherein a top part of the roofing tile is attached to and overlaid by the overlaying and connecting portion of a roofing tile hanging portion of the roofing tile hanger plate such that at least substantially all, or all, of said tile overlaying and connecting portion overlays the roofing tile and the roof attachment portion of the tile hanging portion of the tile hanger plate extends vertically above the top edge of the roofing tile.

Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a roofing tile hanger embodiment of the invention that is sized and configured to be used with three roofing tiles.

FIG. 2 shows a cross-section of a portion of FIG. 1.

FIG. 3 shows an installation configuration for a roof of roofing tiles mounted to roofing tile hangers according to the embodiment shown in FIG. 1.

FIG. 4A shows a roofing tile hanger embodiment of the invention that is sized and configured to be used with a single roofing tile.

FIG. 4B shows the embodiment of FIG. 4A joined to a single roofing tile using fasteners.

DETAILED DESCRIPTION OF THE INVENTION

The invention provides roofing tile hanger plates for mounting one or multiple roofing tiles to the roof of a structure and related assemblies of the hanger plates and tiles. The hanger plates are designed to direct water away from the seams between horizontally adjacent roofing tiles and thereby reduce water penetration to an underlying roof. In addition, the roofing tile hanger plates of the invention permit less of an actual tile to be used below an overlying tile in comparison to a conventional tile roofing installation. Since the per area weight of the roofing tile plates of the invention may be much less than that of the tile itself, the overall weight can be reduced in comparison to a conventional roofing tile installation. Thus, roofing tile installations according to the present invention can mitigate the need for reinforcement of a roof structure that is otherwise commonly encountered with conventional roofing tile installations.

One embodiment of the invention provides a roofing tile hanger plate that includes:

a vertical dimension, a horizontal dimension and an expansive surface on each of two sides,

-   -   at least one tile hanging portion having a horizontal dimension         and sized and configured to attach to one roofing tile, such as         an at least substantially rectangular roofing tile that is at         least substantially flat on both sides (a slab type tile), said         tile hanging portion having a vertically-oriented horizontal         midline and including:     -   a lower, tile overlaying and connecting portion having a bottom         edge and a linear top edge wherein on each side of the midline a         vertical recess (or “cutout”) is formed that extends from the         bottom edge of the lower, tile overlaying and connecting portion         toward but does not reach the top edge of the lower, tile         overlaying and connecting portion; and

a roof attachment portion extending above and from the lower, tile overlaying and connecting portion.

The tile hanger plate may, for example, have one or a plurality, such as two, three, four, five, or more horizontally sequential tile hanging portions. Multiple-tile, tile hanging portion embodiments also provide the advantage of permitting roofs to be installed in a more rapid and streamlined manner than one-tile-at-time installations.

Each of the recesses is positioned between the midline of the tile hanging portion of the hanger plate and the lateral (horizontal) boundaries of the portion which corresponds to (is coextensive with) where the sides of an attached tile will be disposed. In this manner, when tiles are installed in a standard configuration in which the midline of an overlying tile coaligns with the seam between two adjacent underlying tiles (see FIG. 4), the recesses collect and direct water that has made its way to the top surface of a tile down the surface of the tile away from the seams formed by laterally adjacent tiles. There may be a single such recess on each side of the midline of a tile hanging portion of a roofing tile hanger plate of the invention and, therefore, a total of two recesses for each such tile hanging portion.

The vertical recesses may be any shape, for example, arch-shaped. In one variation, the vertical recesses are arch-shaped with vertical sides perpendicular to the horizontal axis of the tile hanger plate. The vertical recesses may, for example, extend upward to any height below the top edge of the lower, tile overlaying and connecting portion, for example, at least 25%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90% of the height of said portion and/or up to 90%, up to 95% or up to 99.9% of said portion. The vertical recesses may, for example, extend upward in the range of 25% to 99.9%, such as 50% to 99.9%, of the height of the lower, tile overlaying and connecting portion of the tile hanging portion of the tile hanger plate.

A related embodiment of the invention provides a roofing tile mounting assembly, that includes:

a roofing tile hanger plate as described herein; and

an at least substantially rectangular roofing tile, such as a rectangular roofing tile, having a top edge, a bottom edge, two side edges and an expansive surface on each side, wherein a top part of the roofing tile is attached to and overlaid by the overlaying and connecting portion of a roofing tile hanging portion of the roofing tile hanger plate such that at least substantially all, or all, of said tile overlaying and connecting portion overlays the roofing tile and the roof attachment portion of the tile hanging portion of the tile hanger plate extends vertically above the top edge of the roofing tile.

Tile hanger plates and tiles may be assembled together at any time prior to installation. In one embodiment, an installation kit including a plurality of tile hanger plates according to the invention with roofing tiles attached thereto is provided. The assembly of tile hanger plates and roofing tiles may be performed manually and/or via automation, e.g., by one or more industrial robots or machines.

A roofing tile may be attached to a roofing tile hanger plate of the invention by any joining or fastening means, for example, via mechanical fasteners and/or adhesives. In one manner, the overlaying and connecting portion of a roofing tile hanging portion of the roofing tile hanger plate may (optionally) be provided with one or more holes that are disposed to align with a corresponding one or holes formed in a roofing tile when the roofing tile is positioned for attachment to the roofing tile hanger plate. A fastener such as a rivet may be placed in the hole(s) and pressed to effectuate the attachment of plate and tile. Alternatively, screw-type fasteners (such as that shown in FIG. 2) may be used.

The hole or holes that may be formed in the tile overlaying and connecting portion of a tile hanging portion of a tile hanger plate are preferably disposed between the lateral (horizontal boundary) of the tile hanging portion and the neighboring vertical recess and not between laterally neighboring vertical recesses of a tile hanging portion. This configuration inhibits water penetration since the seam between overlying tiles will be coaligned with the midline of the underlying tile hanging portion in a standard roofing installation configuration. In a related variation, no holes whatsoever are formed in the entire vertically-extending area between or above the vertical recesses of a tile hanging portion of a tile hanger plate according to the invention.

The roof attachment portion of a tile hanging portion of a roofing tile hanger plate may take different forms and shapes. It may, for example, be at least substantially rectangular and at least substantially flat sheet portion that can be bent down toward a roof to which it is fastened. The roof attachment portion of a roofing tile hanger plate according to the invention may have one or more holes through which fasteners such as screws or nails can be driven to attach the roofing tile hanger plate to an underlying roof. Such holes may be positioned at or near the vertical top of the roof attachment portion of a roofing tile hanger plate. Within each tile hanging portion of a tile hanger plate, such holes may be laterally disposed to the distant (outside) sides of the vertical recesses of the tile hanging portion (rather than above or between the vertical recesses of a tile hanging portion).

The roof attachment portion of a tile hanging portion of a roofing tile hanger plate may include:

a lower at least substantially rectangular spanning portion having a bottom edge and a top edge, the bottom edge of the lower portion continuous with and forming a bend along a horizontal bend line with the top edge of the lower, tile overlaying and connecting portion, wherein the lower at least substantially rectilinear spanning portion bends beneath the plane defined by the lower, tile overlaying and connecting portion; and

an upper at least substantially rectangular portion of the roof attachment portion having a bottom edge and a top edge, the bottom edge of the upper at least substantially rectilinear portion of the roof attachment portion continuous with and forming a bend along a horizontal bend line with the top edge of the a lower at least substantially rectilinear spanning portion, wherein the planes defined by the lower, tile overlaying and connecting portion and the an upper at least substantially rectilinear portion of the roof attachment portion are at least substantially parallel. The vertical dimension of the upper at least substantially rectangular portion of the upper roof attachment portion of the roofing tile hanger plate may be smaller than the vertical dimensions of the lower at least substantially rectilinear portion of the upper roof attachment portion of the roofing tile hanger plate.

The roofing tile hanger plates of the invention may be formed from any material such as a metal/metallic alloy, for example stainless steel or galvanized steel, or a plastic/polymer sheet, for example polypropylene, and by any means known in the art. In the case of metallic embodiments, the hanging plates of the invention may, for example, be manufactured from metallic sheet stock using conventional metal stamping, cutting and/or bending equipment. In the case of polymer embodiments, the hanging plates may, for example, be manufactured by injection molding and/or press molding of polymer sheet stock. A roofing tile hanger plate according to the invention is preferably a unitary, i.e., one-piece, structure.

The invention is further described with respect to the appended figures, as follows.

FIG. 1 shows a roofing tile hanger plate embodiment 101 of the invention that is sized and configured to be used with three roofing tiles. The tile hanger plate includes three vertical sections, from bottom to top: a tile overlaying and connection section 102; a spanning section 103; and an upper roof attachment section 104. As shown, each of sections 102-104 is planar in configuration. Section 102 covers the top part of the front surface of the roofing tiles to which it attaches; section 103 bends on a horizontal linear edge, that is coaligned with the horizontal top edges of the tiles, toward the back surface of the tiles; section 104 then bends back a bit along a horizontal bend line at or around the depth of the back surface of the attached roofing tile. The planes of sections 102 and 104 may, but need not be, at least substantially parallel to one another. The tile hanger plate shown has three horizontally sequential tile hanging portions 105A-105C, each sized and configured to attach to a single roofing tile. Roofing tiles 121 and 122 are shown attached to tile hanging portions 105B and 105C, respectively. For the sake of illustration, tile hanging portion 105A is shown without an attached tile.

As exemplified by vertically-oriented horizontal midline 106 for tile hanging portion 105A, each of the tile hanging portions has a horizontal midline. On each side of horizontal midline 106 and each of the horizontal midlines of the tile hanging portions, there is disposed a recess, exemplified by 107A and 107B that extends vertically upward from the bottom of tile hanger plate 101. As shown, each of the vertical recesses is disposed midway between the midline of a tile hanging portion and the horizontal boundary of the tile hanging portion. The vertical recesses or “cutouts” shown have a preferred configuration of an arch with vertical sides that are perpendicular to the horizontal axis of the tile hanger plate. As exemplified by holes 108A and 108B in tile hanging portion 105A, between each cutout and the near horizontal boundary of the tile hanging portion is a hole size and configured to accommodate a fastener. In tile hanging portion 105C, a screw-type bolt fastener 118B is shown in one such hole. As exemplified by holes 109A and 109B in tile hanging portion 105A, vertical section 104 has a pair of holes formed therein for each tile hanging portion that are sized and configured to receive a fastener such as a screw or nail for attachment of roof tile hanger plate 101 with tiles joined thereto to an underlying roof structure.

FIG. 2 shows a cross-section of a portion of FIG. 1 in further detail. Section 102 in tile hanging portion 105C and tile 122 each have a pair of holes that are mutually disposed to form a passage when the tile is attached to the tile hanging portion. Threaded shaft fastener 119 is inserted from the back side through the hole in tile 122 and passes through the corresponding hole in section 102. Bolt fastener 118B is screw inserted into the threaded shaft provided by threaded shaft fastener 119. As shown, the head of each of 118B and 119 are slotted to accommodate a conventional screwdriver. Any suitable type of fastener head may be used.

FIG. 3 shows an installation configuration for a roof of roofing tiles mounted to roofing tile hangers according to the embodiment shown in FIG. 1. Tile hanger plate 301 is joined to three roofing tiles 321A-C and is attached to a roof in a first bottom row of mounted tiles. Tile hanger plate 302 is joined to three roofing tiles 322A-C and is attached to the roof in a second row of mounted roofing tiles that partially overlays the first row and is horizontally offset from the first row by the distance of half a tile width. Tile hanger plate 303 is joined to three roofing tiles (see 323A and two neighboring tiles) and is attached to the roof in a third row of mounted roofing tiles that partially overlays the second row and is horizontally offset from the second row by the distance of half a tile width (but has no horizontal offset with respect to the first row of tiles). Tile hanger plate 304 is joined to three roofing tiles (such as 324C) and is attached to the roof in a fourth row of mounted roofing tiles that partially overlays the third row and is horizontally offset from the third row by the distance of half a tile width (but has no horizontal offset with respect to the second row of tiles). Tile hanger plate 305 is joined to three roofing tiles (such as 325A) and is attached to the roof in a fifth row of mounted roofing tiles that partially overlays the fourth row and is horizontally offset from the fourth row by the distance of half a tile width (but has no horizontal offset with respect to the third row or first row of tiles). This pattern may be repeated over the entire surface of a roof.

FIG. 4A shows a roofing tile hanger plate embodiment 401 of the invention that is sized and configured to be used with a single roofing tile. Thus, this embodiment includes one tile hanging portion as previously described herein. Tile hanger plate 401 includes two arch-shaped cutouts, 407A and 407B, one on each side of the horizontal midline of the hanger plate. Two holes 408A and 408B are provided for attachment of the roofing tile hanger plate to a roofing tile in which corresponding holes are formed. Optional holes 409A and 409B are formed in the upper roof attachment portion of roofing tile hanger 401 to accommodate fasteners such as screws or nails for roof attachment. FIG. 4B shows roofing tile hanger 401 of FIG. 4A joined to a single roofing tile 421 using screw-type fasteners 418A and 418B.

As shown in the accompanying drawings, roofing tile hanger plates according to the invention may have an at least substantially rectangular profile, such as a rectangular profile, except for the interruption provided by the vertical recesses (cutouts). Edges on various corners may also be rounded.

One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses may occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the claims. 

1. (canceled)
 2. The roofing tile mounting assembly of claim 13, wherein the at least one tile hanging portion of the roofing tile hanger plate comprises a plurality of horizontally adjacent tile hanging portions, each of said tile hanging portions having a vertically-oriented horizontal midline and comprising: a lower, tile overlaying and connecting portion having a bottom edge and a linear top edge wherein on each side of the midline a vertical recess is formed that extends from the bottom edge of the lower, tile overlaying and connecting portion toward but does not reach the top edge of the lower, tile overlaying and connecting portion; and a roof attachment portion extending above and from the lower, tile overlaying and connecting portion.
 3. The roofing tile mounting assembly of claim 13, wherein the roof attachment portion of the roofing tile hanger plate comprises: a lower at least substantially rectangular spanning portion having a bottom edge and a top edge, the bottom edge of the lower portion continuous with and forming a bend along a horizontal line with the top edge of the lower, tile overlaying and connecting portion, wherein the lower at least substantially rectilinear spanning portion bends beneath the plane defined by the lower, tile overlaying and connecting portion; and an upper at least substantially rectilinear portion of the roof attachment portion having a bottom edge and a top edge, the bottom edge of the upper at least substantially rectilinear portion of the roof attachment portion continuous with and forming a bend along a horizontal line with the top edge of the a lower at least substantially rectilinear spanning portion.
 4. The roofing tile hanger plate of claim 3, wherein the planes defined by the lower, tile overlaying and connecting portion of the roofing tile hanger plate and the upper at least substantially rectilinear portion of the roof attachment portion of the roofing tile hanger plate are at least substantially parallel.
 5. The roofing tile mounting assembly of claim 3, wherein the vertical dimension of the upper at least substantially rectangular portion of the upper roof attachment portion of the roofing tile hanger plate is smaller than the vertical dimension of the lower at least substantially rectangular portion of the upper roof attachment portion of the roofing tile hanger plate.
 6. The roofing mounting assembly tile of claim 13, wherein at least one hole is formed in the lower, tile overlaying and connecting portion of the roofing tile hanger plate horizontally adjacent to one of the recesses formed therein.
 7. The roofing tile mounting assembly of claim 6, wherein the at least one hole is formed on the side of a recess that is opposite the side of the recess adjacent to the vertically-oriented horizontal midline of the tile hanging portion.
 8. The roofing tile mounting assembly of claim 7, wherein no holes are formed in the lower, tile overlaying and connecting portion of the roofing tile hanger plate between the recesses formed therein.
 9. The roofing tile mounting assembly of claim 3, wherein at least one hole is formed in the upper at least substantially rectilinear portion of the roof attachment portion of the roofing tile hanger plate, wherein each of said at least one hole is horizontally disposed on the side of one of the recesses of the lower, tile overlaying and connecting portion vertically therebelow that is opposite the side of the recess that is adjacent to the vertically-oriented horizontal midline of the tile hanging portion of the roofing tile hanger plate.
 10. The roofing tile mounting assembly of claim 9, wherein no hole is formed in the upper at least substantially rectilinear portion of the roof attachment portion of the roofing tile hanger plate vertically above the area of the lower tile overlaying and connecting portion between the recesses formed therein.
 11. The roofing tile mounting assembly of claim 10, wherein no hole is formed in the upper at least substantially rectilinear portion of the roof attachment portion of the roofing tile hanger plate vertically above the recesses.
 12. The roofing tile mounting assembly of claim 13, wherein the roofing tile hanger plate is formed from a unitary sheet of metal.
 13. A roofing tile mounting assembly, comprising: (a) a roofing tile hanger plate comprising: a vertical dimension, a horizontal dimension and an expansive surface on each of two sides at least one tile hanging portion, said tile hanging portion having a vertically-oriented horizontal midline and comprising: a lower, tile overlaying and connecting portion having a bottom edge and a linear top edge wherein on each side of the midline a vertical recess is formed that extends from the bottom edge of the lower, tile overlaying and connecting portion toward but does not reach the top edge of the lower, tile overlaying and connecting portion; and a roof attachment portion extending above and from the lower, tile overlaying and connecting portion; and (b) a separate at least substantially rectangular at least substantially flat roofing tile having a top edge, a bottom edge, two side edges and an expansive surface on each side, wherein only a top part of the roofing tile is attached to and overlaid by the overlaying and connecting portion of a roofing tile hanging portion of the roofing tile hanger plate such that all of said tile overlaying and connecting portion overlays the roofing tile and the roof attachment portion of the tile hanging portion of the tile hanger plate extends vertically above the top edge of the roofing tile.
 14. The roofing tile mounting assembly of claim 13, wherein a hole is formed in the tile overlaying and connecting portion of the tile hanging portion of the tile hanger plate and a hole is formed in the roofing tile, said holes mutually disposed to form a passage for a fastener when the roofing tile is overlaid by the tile overlaying and connecting portion of the tile hanging portion of the tile hanger plate.
 15. The roofing tile mounting assembly of claim 14, wherein a fastener partially disposed within the hole attaches the tile hanger plate to the roofing tile. 